INSTALLATION AND INSTRUCTION MANUAL
TDDL15 TRAFFIC DIRECTORS
TDDL15-36 Series
TDDL15-42 Series
TDDL15-47 Series
PLITSTR192 REV. D 6/21/12
Due to continuous product improvements, we must reserve the right to change any
specifications and information, contained in this manual at any time without notice.
Star Headlight & Lantern Co., Inc. makes no warranty of any kind with regard to this
manual, including, but not limited to, the implied warranties of merchantability and
fitness for a particular purpose. Star Headlight & Lantern Co., Inc. shall not be liable
for errors contained herein or for incidental or consequential damages in connection
with the furnishing, performance, or use of this manual.
Table of Contents
Table of Contents
Warnings, Dimensions, and General Notes 1-2
Table of ContentsTable of Contents
MOUNTING INSTRUCTIONS 3-7
Standard Mounting 3-4
TDDL15-47CV Mounting 5
NOTICE
TDDL15-47TA Mounting 6-7
ELECTRICAL CONNECTIONS 8-9
JUMPER SETTINGS 10
OPERATION 11-13
TROUBLESHOOTING 13
WARRANTY 14
SERVICE 14
Please Note: These instructions are provided as a general guideline only. Specific
mounting and/or wiring, may be necessary and are the sole responsibility of the
installer. Star Headlight & Lantern Co., Inc. assumes no responsibility for the
integrity of the installation for this or any of its products.
-i-
Important
collision, personal injury and/or death. Star Headlight & Lantern Co., Inc., and its
subsidiaries shall not be held responsible for damages directly or indirectly caused by
improper use of this product. Always carefully consider the effect on traffic that the
selected light pattern will have before engaging the lights.
: This product is used to direct traffic. Improper use may result in vehicular
The TDDL15
technology. This warning light is comprised of ultra-high intensity LEDs
that are operated by a micro-controller to efficiently produce light output
with lifetimes up to 100,000 hours.
uses state-of-the-art Light Emitting Diode (LED)
#10 Carriage Bolt
1
1
"
2
5
1
16
"
Slot for
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Before beginning the installation:
• Determine where the Traffic Director is to be mounted (on your lightbar, on your roof,
in your rear window, etc.
• Check to see that there are no obstructions hindering the visibility of your traffic
director.
• Then select a location to mount your controller. The controller must be located in a
dry location out of direct sunlight, free of dirt and dust. Under the vehicle's
instrument panel is usually the best choice.
Once you have selected these locations, determine the path your cable, which
connects the controller to the Traffic Director, will take. If you are installing a
TDDL15-47 or TDDL15-36 the cable should exit the left side of the Traffic Director
when you are facing both the stick and the controller. If you are installing the
TDDL15-42 the cable should exit the right side of the Traffic Director when you are
facing both the stick and the controller.
• Be sure the cable attached to your Traffic Director is long enough for proper
installation. If it is too short, you will need to order a longer harness to replace the
one that came with the lightstick. Star does not recommend “splicing in”
additional cable when the supplied cable is too short (or if you damage the
original harness during installation).
Available lengths include:
15’ SWH-271-ARO-15
22’ SWH-271-ARO-22
30’ SWH-271-ARO-30
45’ SWH-271-ARO-45
60’ SWH-271-ARO-60
Limited mounting hardware is supplied because of the many mounting possibilities of
these products. The installer assumes responsibility for the integrity of the installation. It is the
sole responsibility of the owner to ensure the traffic director is secure.
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Mounting Instructions
The following mounting instructions describe the standard, most common
way to mount this light. This method may or may not apply to your vehicle.
Because vehicles can vary widely in their design, it may be necessary to
configure the brackets differently than described. Some applications may
require you to design your own custom brackets. The installer assumes all
responsibility for the integrity of the installation. It is the sole
responsibility of the owner to ensure the traffic director is secure.
Standard TDDL15 Mounting
1. The standard TDDL15 traffic directors come
with two “L”-Brackets (P/N P30147-80PC) to
assist in mounting it to a lightbar or other
secure base.
The TDDL15-47CV and TDDL15-42TA will
use alternate mounting brackets discussed on
pages 5-7.
Also included are four flat washers and four
flanged nuts to use the with the four #10
carriage bolts pre-installed on your traffic
director.
2. Each bar light assembly comes equipped with a slot along the back of the entire
length of the extrusion that will retain the head of #10 carriage bolts. Four carriage
bolts should be pre-installed in this slot.
These bolts can be used to mount the lightstick directly
to your mounting surface, or you can mount the
lightstick to the “L” brackets.
Please note that the mounting
slot must be closer to the lower
edge of the light when you
mount it to allow for
proper draining
through the weep
holes. Failure to
mount this bar with
the slot towards the
bottom will void the
warranty.
(2) P30147-80PC
PRE-INSTALLED
3. If you are mounting your lightstick directly to your vehicle and need to replace the
preinstalled carriage bolts with longer ones, proceed as follows:
A. Remove the end-cap on the opposite
end of the cable and slide the original
bolts out of the channel.
B. Slide the necessary number of new
bolts (usually four for most applications)
into the channel on your traffic director.
C. Reattach the endcap. When reinstalling
the end-cap make certain the gasket is
Remove one of
the endcaps
and slide the
bolt heads into
the slot.
positioned correctly.
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(Mounting CONT’D)
4. Whether you are using the L-Brackets or not, slide the bolts to their desired location
along the track and mount the bolts through pre-drilled holes in your vehicle or through
the mounting brackets. Use one each of the enclosed flat washer and nut on each
bolt. If you are using the L-brackets provided, you will need to supply the appropriate
bolts or other fasteners to attach the brackets to your mounting surface.
Please note that there is a label on the extrusion that indicates
which side should be facing up. If you do not have the proper
side up, the lightstick will direct traffic in the opposite direction.
In addition, there are ventilation holes in the endcaps to help
eliminate any condensation. If the lightstick is mounted on the
exterior of the vehicle, these ventilation holes must remain
towards the bottom of the lightstick.
CAUTION: Be sure to carefully inspect and test the integrity
of your mount.
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(Mounting CONT’D)
TDDL15-47CV Mounting
(Ford Crown Victoria Mounting)
1. The 274-RDCV mounting brackets
enclosed with the 47” TDDL15-47CV are
designed to mount directly to the child
restraint fixtures inside the vehicle on the
rear deck, facing out the rear window.
2. Using the carriage bolt enclosed with the
brackets, mount one of the 274-RDCV brackets
to each of the child restraint fixtures located on
the rear deck of the vehicle. Secure them with
the washers and lock nuts provided.
3. Slide the bolts along the track until they are spaced the
same distance apart as the two child restraint fixtures.
Use a flat washer and nut on the bolt to mount the
lightstick to the brackets now attached to the
child restraint fixtures. Leave the nuts loose
until you adjust the bar horizontally,
centering it in the rear window.
Once it has been adjusted to
the desired location,
tighten the nuts,
securing the
lightstick.
274-RDCV
4. The TD77-2 Controller comes
with a “U”-Bracket. If that bracket
will not work for your application,
the two “L”-Brackets included in
the 274-RDCV kit can be used
instead.
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(Mounting CONT’D)
TDDL15-42TA
(Chevy Tahoe Mounting)
1. The TD92-7KTA is included with the TDDL15-42TA.
It includes (2) lightstick mounting brackets and
(4) 1/4” x 3/4” self-drilling hex head screws.
2. These brackets are designed to
TD92-7KTA
TAHOE BRACKET KIT
mount to the roof framework at the
rear of the vehicle. Pull down the
overhead plastic trim from the rear
of the Chevy Tahoe.
3. Locate the third upholstery “push-it”
mounting hole from end.
4. Place the large, oblong hole in the
bracket over the upholstery
mounting hole, with the wider edge
of the bracket facing towards the
rear of the vehicle.
5. Secure the bracket with two ¼” x
¾” self-drilling hex head screws
through the two smaller holes in the
corners of the bracket.
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(Mounting CONT’D)
6. Repeat steps 3-5 on other side of
vehicle.
7. Replace the plastic trim piece.
8. Use the 1/4-20 Bolts installed on
the back of the traffic director with
the washers and lock nuts
enclosed with the traffic director,
to secure the traffic director to the
bracket.
Because of the wide variety of mounting applications, Star Headlight
& Lantern Co., Inc. assumes no responsibility for the secure
mounting of this light. It is the responsibility of the installer and/or
owner to ensure the lightbar is mounted securely. Check your light
every time you use the vehicle to ensure that it is mounted securely.
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Electrical Connections
1. The cable attached to your Traffic Director should have a green connector (part #CPSS-153)
attached to it. Eight colored 18 AWG wires, one bare drain wire, and a large red 12AWG wire
should already be connected from the cable to the connector.
2. Connect a ground wire to the interior empty terminal on the green connector. (See diagram
above) The corresponding terminal plugs into the outlet on the back of the controller and is
marked BAT-.
3. Supply power for the unit from a fused, +12 VDC source capable of delivering at least
15 amps of current (use a 20 amp fuse). Star recommends the use of an ignition
switched supply to avoid the possibility of draining the vehicle's battery should the unit
be accidentally left on.
4. Connect your power supply to the terminal on the green connector that corresponds to
the outlet on the back of the controller marked BAT+.
5. The lamp brightness will be somewhat diminished if a large voltage drop exists between
the vehicle's battery and the controller. Don't forget to fuse the feed and signal wires
at their source, with appropriate values. It is imperative that you supply a ground wire to
the terminal marked "BAT -" on the controller; you must not let the controller's case
supply ground. Use 16 AWG
6. Your Traffic Director should now be ready to operate.
It is imperative that you supply a ground wire to the terminal marked
"BAT -" on the controller. You must not let the controller's case supply
ground. Use 12 AWG wire for all power and ground connections
If you are utilizing the On/Off Switch bypass option AND you have other devices
connected to the same bypass switch, you MUST connect the bypass power through a
relay to prevent the other devices from powering up when you use the standard On/Off
switch on the TD controller. Please contact our Customer Service Department if you
need further details on this.
(14AWG for 40’+)
wire for all power and ground connections.
-8-
(Wiring CONT’D)
Wiring for Optional Automatic Activation
1. The Traffic Director may also be wired to automatically bypass the ULB42-TD--2 controller On/
Off switch and turn on through the use of an alternate power source (i.e. lightbar switch, siren
switch, reverse switch, etc.).
2. When you apply +12VDC to the 12AWG wire supplying the stick with power, you will bypass
the On/Off switch and activate the Traffic Director. When activated, the Traffic Director will
automatically enter the "Warn" pattern. Please note: If any other lights are connected to
this “bypass” circuit they will activate any time the traffic director is powered up unless
they are isolated in some way (e.g. diode or relay).
Removable Harness
The TDDL15 series lightsticks come equipped with a removable harness. If for any reason you
need to remove the light from the vehicle, or need to replace the harness, you can remove either,
without having to remove both. Approximately 6” from the light, along the harness, there is a quick
disconnect that can separated. See page 2 for a list of harness lengths available.
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Optional Jumper Settings
If the standard traffic directing mode is acceptable, skip this section.
The TD77-2 control box and the ULB42-TD-2
control box are identical except for the factory
default setting of a jumper located inside the
control box. This jumper will control the output of
the two arrays on each end. The TD77-2 comes
with the jumper defaulted for standard operation.
Optionally you may wish to set the jumper so that your arrowstick operates in "Phantom" mode. In
the “Phantom” mode, the end lights are not part of the “traffic directing” patterns. When the Alt
button is pressed, both of the end lights will flash back and forth in a “warn” type display. (In the
"standard" mode, the end lights will follow the normal “traffic directing” pattern you select on the
control box.) If you wish to operate your traffic director in Phantom Mode, (6-head traffic directing),
follow the instructions below to remove the cover and change the jumper setting. If the standard
mode is acceptable, skip this section.
These Traffic Directors have 8 heads or LED arrays.
When the control box jumper is in the "Phantom Mode" setting (see diagram
below) only the center 6 arrays will be utilized during the Left, Center Out,
and Right patterns. The outer two heads or arrays with flash alternately.
TD77-2
Arrow stick Control Box Cover Removal
Remove the four recessed Philip head screws (two on each
side of the arrow stick control box). Remove the top cover
by sliding it towards the front of the unit.
TD77-2 and ULB42-TD-2 Controllers
Locate the extra jumper
location near the fuses. Move
the jumper from the “Option”
jumper location near the center
of the board over to the extra
jumper section.
Jumper moved to
extra jumper holder
from 1st pair of pins
for Phantom Mode
-10-
For standard operation (8-light
traffic directing), the first jumper
remains in the TD77-2 spot
TD77-2
Operation
Important: This product is used to direct traffic. Improper use may
result in vehicular collision, personal injury and/or death. Star
Headlight & Lantern Co., Inc., and its subsidiaries shall not be held
responsible for damages directly or indirectly caused by improper
use of this product. Always carefully consider the effect on traffic
that the selected light pattern will have before engaging the lights.
1. Your new traffic director is a powerful tool that can aid you in traffic control; or if used
improperly, it could direct traffic into a dangerous situation.
USE CAUTION!!!
2. Operation of your Traffic Director is straightforward. The controls include an On/Off
switch, four Pattern Select buttons, and three additional "option" buttons.
TD77-2 Controller
3. Turn the vehicle's ignition switch to the on or accessories position to supply power to the
controller (if necessary) and press the On/Off switch on the control box. The LED
display should begin to show the "Warn" pattern and the "Warn" label should glow red.
4. Select the desired pattern (if
different from the current pattern) by
using any of the Pattern Select
buttons. The Pattern Select
buttons include Left, Center, Right,
and Warn. The selected pattern
label should change to red and the
roof display should mimic exactly the
display on the controller.
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(Operation CONT’D)
5. The ULB42-TD-2 controller also has three "option" buttons:
Fast, Dim, and Alt.
Dim Button
This Traffic Director has three different levels of
“brightness”. This allows the user the option to dim the
light for nighttime operation. When the "Dim" button is
pressed once the "Dim" label will change from green to red and the Traffic Director will
dim slightly (50%). Pressing it a second time will change the button to orange and the
traffic director will dim further (15%). Pressing it a third time will return the Traffic
Director to full brightness.
Alt and Fast Buttons
The Alt and Fast buttons have a different effect on the Left, Center Out, and Right
patterns than the effect they have on the Warn pattern.
Alt Function for Left / Center Out / Right Directional Patterns
Note: The options described below only apply if you have your controller in Standard Mode. If
you set the jumper for Phantom Mode (as described on page 10) the Alt button will only
When your controller has the jumper set for Standard Mode (default), and when you
enable or disable the two outer flashing arrays/heads and you should skip to the next page.
have the Left, Center-Out, or Right pattern selected, the "Alt" button will scroll through
eleven different alternate versions of that pattern. The version selected will apply to all
three directional patterns and will remain selected even if the unit is powered off.
• The first four versions (A-D) are 7-light versions designed for use with traffic
directors that may have an arrow painted on each end
• The next four (E-H) are the same as the first four, but utilize all eight lights.
• I and J provide two additional 8-light versions.
(not applicable to TDDL15)
• The final version (K) uses only the center six lights. The outer two lights are rapidly
flashed (similar to Phantom mode).
7-Light Patterns
A. Progressive 7 - Starts with one light and consecutively adds lights to the pattern until they
B. End Blink 7 - Same as the Progressive 7 version with the exception that the last light will
C. Dual Light 7 - Only two lights will be lit at the same time. The two lights will "roll" in the
D. Progressive 7 T13 - Superfast Progressive 7
8-Light Patterns
E. Progressive 8 - Same as the 7-Light version above, except all 8 lights are used.
F. End Blink 8 - Same as the 7-Light version above, except all 8 lights are used.
G. Dual Light 8 - Same as the 7-Light version above, except all 8 lights are used.
H. Progressive 8 T13 - Superfast version of Progressive 8
I. Quad Light 8 T13 - 4-Head rolling version
J. Snake 8 T13 - 8-head rolling version (aka Progressive On, then Progressive Off)
(California Title 13 and SAE compliant *)
6-Light Pattern
K. Outer Flashing - Same as the Progressive pattern, but only uses the six center lights. The
* When used with an approved lightstick
are all lit. The first light (usually in the shape of an arrow) will not
illuminate.
double blink.
direction of the selected pattern. The first light will not illuminate in this
pattern.
(California Title 13 and SAE compliant *)
(California Title 13 and SAE compliant *)
(California Title 13 and SAE compliant *)
.
outer two lights alternate quickly back and forth.
.
-12-
(Operation Jumper in TD77-2 Mode CONT’D)
Fast Function for Left / Center Out / Right Patterns
The "Fast" button provides the user with the option to display any of the patterns (Left,
Center Out, or Right) in a "faster" mode. Pressing the "Fast" button once should
change the "Fast" label to red and speed up the pattern. Pressing the button again will
change the "Fast" label back to green and revert the pattern to the standard speed.
Alt and Fast Functions for Warn Pattern
When the Traffic Director is in the Warn pattern, the Alt button will scroll through 10
different versions of “WARN” patterns. The 10 versions differ depending upon if you
have the Fast button activated or not. Review the chart below for the different versions
that can be scrolled through.
Fast Button De-Activated Fast Button Activated
1. 6-Head Warn Pattern 1. 6-Head Random 1 †
2. 6-Head Warn w/Alternating Ends 2. 6-Head Warn w/Alternating Ends
3. 8-Head Warn 3. 8-Head Random 2 †
4. Search Light 4. Search Lights †
5. Side Band Alternate 5. Side Band Alternate †
6. Random 1 † 6. Hyper Random 1 †
7. Random 2 † 7. Hyper Random 2 †
8. 8-Head Warn T13 † 8. 8-Head Warn T13 †
9. 8-Head X T13 † 9. 8-Head X T13 †
10. 8-Head Jumble † 10. 8-Head Jumble †
† - These patterns are not recommended for use with the TD77 or other incandescent traffic directors
T13 - California Title 13 and SAE compliant patterns when used with approved sticks
The TDDL15 has 8 LED arrays.
6-Head WARN patterns only utilize the center 6 arrays
6. When using the Traffic Director, always be sure that the pattern selected is appropriate
for the present hazard condition. The potential danger in displaying an
inappropriate pattern cannot be overstated.
Once your Traffic Director is installed, please test all the patterns, options, and alternate versions to
familiarize yourself with the various patterns and the operation of the controller.
Troubleshooting
The TDDL15 lightsticks can be easily disassembled for
troubleshooting purposes. To gain access to the interior of the light,
remove the two screws in the endcap with the wire harness. The
entire assembly should slide out of the housing allowing you to
inspect the internal wiring looking for broken connections. DO NOT
OVERTIGHTEN SCREWS WHEN REASSEMBLING!!!
The TD77-2 controller contains two ATO "blade-type" fuses located in the back of the
controller. The fuses are accessible from the rear of the controller. The 20 amp fuse
controls power to the bar light assembly, while the 2 amp fuse powers the controller. If the
20 amp fuse blows the controller will continue to function normally, however, the lightstick
will not. It is important to note that under normal circumstances the only reason a fuse will
blow is because there is a fault in the system. If a fuse blows repeatedly it is a signal
that something is wrong. Do not replace a blown fuse with anything other than the same
amperage rating as marked on the rear panel of the controller; doing so may damage the
unit or start a fire. Likely causes of blown fuses are improper wiring or harness damage.
-13-
Service
LED FIVE YEAR LIMITED WARRANTY
The manufacturer warrants this LED light against factory defects in material and
workmanship for five years after the date of purchase. The owner will be responsible for
returning to the Service Center any defective item (s) with the transportation costs
prepaid. The manufacturer will, without charge, repair or replace at its option,
products, or part(s), which its inspection determines to be defective. Repaired or
replacement item(s) will be returned to the purchaser with transportation costs prepaid
from the service point. A copy of the purchaser's receipt must be returned with the
defective item(s) in order to qualify for the warranty coverage. Exclusions from this
warranty include, but are not limited to, domes, and/or the finish. This warranty shall not
apply to any light, which has been altered, such that in the manufacturer's judgment,
the performance or reliability has been affected, or if any damage has resulted from
abnormal use or service.
There are no warranties expressed or implied (including any warranty of merchantability
or fitness), which extend this warranty period. The loss of use of the product, loss of time,
inconvenience, commercial loss or consequential damages, including costs of any
labor, are not covered. The manufacturer reserves the right to change the design of
the product without assuming any obligation to modify any product previously
manufactured.
This warranty gives you specific legal rights. You might also have additional rights that
may vary from state to state. Some states do not allow limitations on how long an
implied warranty lasts. Some states do not allow the exclusion or limitation of incidental
or con sequential damages. Therefore, the above limitation(s) or exclusion(s) may not
apply to you.
If you have any questions concerning this or any other product, please contact our
Customer Service Department at (585) 226-9787.
If a product must be returned for any reason, please contact our
Customer Service Department to obtain a Returned Materials Authorization
number (RMA #) before you ship the product back.
Please write the RMA # clearly on the package near the mailing label.
-14-
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